System and method for automated optical inspection of industrial gas turbines and other power generation machinery

ABSTRACT

Internal components of power generation machinery, such as gas and steam turbines are inspected with an optical camera inspection system that is capable of automatically positioning the camera field of view (FOV) to an area of interest within the machinery along a pre-designated navigation path and capturing images without human intervention. Automatic camera positioning and image capture can be initiated automatically or after receipt of operator permission. The pre-designated navigation path can be defined by operator manual positioning of an inspection scope within the power machine or a similar one of the same type and recording of positioning steps for future replication. The navigation path can also be defined by virtual simulation.

REFERENCE TO CO-PENDING APPLICATIONS

This application claims the benefit of co-pending United States utilitypatent application entitled “System And Method For Automated OpticalInspection Of Industrial Gas Turbines And Other Power GenerationMachinery With Multi-Axis Inspection Scope”, filed Jan. 31, 2012 andassigned Ser. No. 13/363,352, and co-pending United States utilitypatent application entitled “System And Method For Automated OpticalInspection Of Industrial Gas Turbines And Other Power GenerationMachinery With Articulated Multi-Axis Inspection Scope”, filed Jan. 31,2012 concurrently herewith and assigned Ser. No. 13/362,387, all ofwhich are incorporated by reference herein.

BACKGROUND OF THE DISCLOSURE

1. Field of the Invention

The invention relates to optical camera systems for nondestructiveinternal inspection of industrial gas turbines and other powergeneration machinery, including by way of non-limiting example steamturbines and generators. More particularly the invention relates to anoptical camera inspection system that is capable of automaticallypositioning the camera field of view (FOV) to an area of interest withinthe machinery and capturing images without human intervention. Automaticcamera positioning and image capture can be initiated automatically orafter receipt of operator permission.

2. Description of the Prior Art

Power generation machinery, such as steam or gas turbines, are oftenoperated continuously with scheduled inspection and maintenance periods,at which time the turbine is taken off line and shut down. By way ofexample, a gas turbine engine often will be operated to generate powercontinuously for approximately 4000 hours, thereupon it is taken offline for routine maintenance, inspection, and repair of any componentsidentified during inspection. Taking a gas turbine off line andeventually shutting it down completely for scheduled maintenance is amulti-day project. Some turbine components, such as the turbine rotorsection, are operated at temperatures exceeding 1000° C. (1832° F.). Theturbine requires 48-72 hours of cooling time to achieve ambienttemperature before complete shutdown in order to reduce likelihood ofcomponent warping or other deformation. During the shutdown phase theturbine rotor is rotated in “turning gear mode” by an auxiliary drivemotor at approximately 10 RPM or less, in order to reduce likelihood ofrotor warping. Other turbine components, such as the turbine housing,are also cooled slowly to ambient temperature.

Once the turbine is cooled to ambient temperature over the course of upto approximately 72 hours internal components of the now static turbinecan be inspected with optical camera inspection systems. Known opticalcamera inspection systems employ rigid or flexible optical bore scopesthat are inserted into inspection ports located about the turbineperiphery. The bore scope is manually positioned so that its field ofview encompasses an area of interest within the turbine, such as one ormore vanes or blades, combustor baskets, etc. A camera optically coupledto the bore scope captures images of objects of interest within thefield of view for remote visualization and archiving (if desired) by aninspector.

If a series of different images of different areas of interest within agiven turbine inspection port are desired, the operator must manuallyre-position the camera inspection system bore scope to achieve thedesired relative alignment of internal area of interest and the field ofview. Relative alignment can be achieved by physically moving the borescope so that its viewing port is positioned proximal a static area ofinterest. Examples of such relative movement of bore scope and staticturbine component are by inserting a bore scope in differentorientations within a static combustor or radially in and out of spacebetween a vane and blade row within the turbine section. Relativealignment can also be achieved by maintaining the bore scope viewingport in a static position and moving the turbine internal component ofinterest into the static viewing field. An example of relative movementof turbine internal component and static bore scope is inspection ofdifferent blades within a blade row by manually rotating the turbinerotor sequentially a few degrees and capturing the image of a blade. Therotor is rotated sequentially to align each desired individual blade inthe row within the camera viewing field.

Complete turbine inspection requires multiple manual relativerepositioning sequences between the camera inspection system viewingport and areas of interest within the turbine by a human inspector.Inspection quality and productivity is subject to the inspection andmanipulation skills of the inspector and inspection team. Inspectionapparatus positioning is challenging due to the complex manipulationpaths between components in a gas turbine. For example, insertion of abore scope through a combustor inspection port in order to inspect theleading edge of first row vanes or related supports requires compoundmanipulations. Improper positioning of inspection apparatus within aturbine potentially can damage turbine internal components. Often aninspection team of multiple operators is needed to perform a manualinspection using known inspection methods and apparatus. In summary,known manual camera inspection procedures and inspection systemmanipulation are time consuming, repetitive in nature, and often requireassistance of an inspection team of multiple personnel. The “humanfactor” required for known manual camera inspection procedures andinspection system manipulation introduces undesirable inspection processvariances based on human skill level differences. Given human skillvariances, some inspection teams are capable of completing inspectionsin less time, achieve better image quality and have lower inspectiondamage risk than other teams. Ideally skills of a high performinginspection team could be captured for use by all teams.

A need exists in the art for optical camera inspection systems andmethods that reduce total time necessary to perform a nondestructiveinternal inspection of power generation machinery, including by way ofnon-limiting example steam or gas turbines and generators than isattainable by known inspection apparatus and methods, so that themachinery can be brought back on line for resuming power generation morequickly during maintenance cycles.

Another need exists in the art for optical camera inspection systems andmethods that are capable of positioning inspection apparatus withinpower generation machinery, including by way of non-limiting examplesteam or gas turbines and generators, consistently and repetitivelywithin an individual machine's inspection cycle or within inspectioncycles of multiple different machines, with minimized risk of damage tomachine internal components, high image quality and quicker inspectioncycling time than is attained by the known manual inspection apparatusand methods.

Yet another need exists in the art for optical camera inspection systemsand methods that help to equalize inspection skill level andproductivity among different inspection teams.

SUMMARY OF THE INVENTION

Accordingly, potential objects of the present invention, jointly orseverally among others, are to create optical camera inspection systemsand methods for power generation machinery, (including by way ofnon-limiting example steam or gas turbines and generators) that comparedto known inspection apparatus and methods: reduce total scheduledmaintenance period time and individual inspection cycle time; positioninspection apparatus consistently and repetitively within an individualmachine's inspection cycle or within inspection cycles of multipledifferent machines, with minimized risk of damage to machine internalcomponents and high image quality; and that help to equalize inspectionskill level and productivity among different inspection teams.

Internal components of power generation machinery, such as gas and steamturbines or generators, are inspected with an optical camera inspectionsystem that is capable of automatically positioning the camera field ofview (FOV) to an area of interest within the machinery along apre-designated navigation path and capturing images without humanintervention. Automatic camera positioning and image capture can beinitiated automatically or after receipt of operator permission. Thepre-designated navigation path can be defined by operator manualpositioning of an inspection scope within the power machine or a similarone of the same type, and recording the sequence of positioning stepsfor future replication. The navigation path can also be defined byvirtual simulation.

These and other objects are achieved in accordance with the presentinvention by a system for internal inspection of power generationmachinery, including generators and industrial gas or steam turbines.The system includes a base for affixation to a power generation machineinspection port. An inspection scope having a proximal end is coupled tothe base, and has at least one degree of motion that is capable ofremote control and actuation by a control system. A camera, having afield of view, is coupled to the inspection scope distal the base, andis capable of remote control and image capture by a control system. Thesystem also has a control system coupled to the inspection scope andcamera, for automatically positioning the inspection scope and camerafield of view along a pre-designated navigation path within a powergeneration machine to an internal area of interest and for capturing acamera image thereof without human intervention.

The present invention also features a method for internal inspection ofpower generation machinery, and includes the steps of providing aninternal inspection system. The inspection system has a base foraffixation to a power generation machine inspection port. An inspectionscope has a proximal end coupled to the base, and at least one degree ofmotion that is capable of remote control and actuation by a controlsystem. A camera, having a field of view, is coupled to the inspectionscope distal the base. The camera is capable of remote control and imagecapture by a control system. The system also has a control systemcoupled to the inspection scope and camera, for automaticallypositioning the inspection scope and camera field of view along apre-designated navigation path within a power generation machine of thetype being inspected to an internal area of interest and for capturing acamera image thereof without human intervention. The method furtherincludes the steps of affixing the base to a power machine inspectionport and providing the navigation path to the control system. Next, thepower machine is inspected by automatically positioning the inspectionscope and camera field of view along the navigation path with thecontrol system and capturing a camera image thereof without humanintervention. The order of steps may be modified when performing thismethod.

The present invention also features a method for inspecting anindustrial gas turbine. First, the gas turbine is shut down to ceasepower generation operation. An internal inspection system is providedthat has a base for affixation to an inspection port of the turbine. Aninspection scope is provided that has a proximal end coupled to thebase, and at least one degree of motion that is capable of remotecontrol and actuation by a control system. A camera, having a field ofview, is coupled to the inspection scope distal the base. The camera iscapable of remote control and image capture by a control system. Theinspection system includes a control system coupled to the inspectionscope and camera, for automatically positioning the inspection scope andcamera field of view along a pre-designated navigation path within thegas turbine to an internal area of interest and for capturing a cameraimage thereof without human intervention. The gas turbine is cooled toan internal temperature of less than 150° C. (300° F.) and the base isaffixed to an inspection port of the gas turbine. A navigation path isprovided to the control system. Thereafter the gas turbine is inspectedby automatically positioning the inspection scope and camera field ofview along the navigation path with the control system and capturing acamera image thereof without human intervention. The camera image orplurality of images is stored for review. The order of steps may bemodified when performing this method.

The navigation path is pre-determined by a number of methods andsubsequently recorded for future replication by the control system ofthe actual inspection scope used in the inspecting step. The navigationpath pre-determination methods may include: prior human controlledpositioning of an inspection scope of the type used in the inspectingstep within the actual inspected gas turbine (or within another gasturbine having the same type of internal structure as the actualinspected gas turbine) along a selected navigation path; humancontrolled simulated positioning of a virtual inspection scope of thetype used in the inspecting step within a virtual power generationmachine of the type being inspected along a selected navigation path;and simulated positioning of a virtual inspection scope and virtualpower generation machine of the type used in the inspecting step along asimulated selected navigation path without human intervention.

The objects and features of the present invention may be applied jointlyor severally in any combination or sub-combination by those skilled inthe art.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the present invention can be readily understood byconsidering the following detailed description in conjunction with theaccompanying drawings, in which:

FIG. 1 is a partial cross sectional schematic view of a known gasturbine;

FIG. 2 is a partial cross sectional schematic view of a known gasturbine showing partial insertion of an optical camera inspection systemembodiment of the present invention into a combustor inspection port;

FIG. 3 is partial cross sectional schematic view of a known gas turbineperforming an inspection of a combustor internal components with theoptical camera inspection system of FIG. 2;

FIG. 4 is partial cross sectional schematic view of a known gas turbineperforming an inspection of the leading edge of row 1 turbine bladeswith the optical camera inspection system of FIG. 2;

FIG. 5 is a perspective schematic view of the optical camera inspectionsystem of the embodiment of FIG. 2, showing available degrees of motionΩ, T, Φ, E and θ;

FIG. 6 is a perspective schematic view of the optical camera inspectionsystem of FIG. 5, in the folded insertion position of FIG. 2;

FIG. 7 is a perspective schematic view of the optical camera inspectionsystem of FIG. 5, in the locked inspection position of FIG. 3;

FIG. 8 is a perspective schematic view of the extension tube mechanismportion of the optical camera inspection system of FIG. 5, showing the Ωand T degrees of motion;

FIG. 9 is a schematic perspective view of an adapter ring of the presentinvention being attached to a turbine inspection port;

FIG. 10 is a schematic elevational view of a camera head articulationand rotation (pan) mechanism of the optical camera inspection system ofFIG. 5, showing the Φ and θ degrees of motion;

FIG. 11 is a schematic plan view of a camera head articulation androtation (pan) mechanism of FIG. 10;

FIG. 12 is a schematic elevational view of a camera head extensionmechanism of the optical camera inspection system of FIG. 5, showing theE degree of motion;

FIG. 13 is a schematic perspective view of the camera head of theoptical camera inspection system of FIG. 5;

FIG. 14 is a schematic exploded perspective view of a camera head of theoptical camera inspection system of FIG. 5;

FIG. 15 is a schematic partial assembly perspective view of the camerahead of FIG. 14;

FIG. 16 is a block diagram of the control box and controls system forthe optical camera inspection system of FIG. 5;

FIG. 17 is a perspective schematic view of an embodiment of a tabletcomputer human machine interface (HMI) for operator remote monitoringand control of the optical camera inspection system of the presentinvention;

FIG. 18 is a partial cross sectional schematic view of a known gasturbine showing insertion of another optical camera inspection systemembodiment of the present invention into two separate turbine sectionrows respective inspection ports;

FIG. 19 is an elevational perspective view of optical camera inspectionsystem embodiment of FIG. 18, showing available degrees of motion T, θand Φ; and

FIG. 20 is an elevational view of the swing prism articulation mechanismfor the Φ degree of motion.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

After considering the following description, those skilled in the artwill clearly realize that the teachings of the present invention can bereadily utilized in optical camera systems for nondestructive internalinspection of power generation machinery, including by way ofnon-limiting example steam or gas turbines and generators. The opticalcamera inspection system is capable of automatically positioning thecamera field of view (FOV) to an area of interest within the machineryand capturing images without human intervention. Automatic camerapositioning and image capture can be initiated automatically or afterreceipt of operator permission. Alternatively, the system may behuman-operated in “manual” mode.

Camera Inspection System Overview

Referring to FIG. 1, embodiments of the present invention facilitateautomated off-line remote visual inspection of gas turbine 30 internalcomponents, including combustors 34, turbine section Row 1 and Row 2fixed vanes 42, 46; leading Row 1 and Row 2 rotating blades 44, 48; andring segments. As shown in FIGS. 2-4 and 18, embodiments of the presentinvention inspection system enables inspection of offline turbines thathave not fully cooled to ambient temperature by attachingremote-actuated optical camera inspection scope probes 60, 220 toturbine inspection ports 36, 50 and 52. Upon attachment the inspectionscope probes 60, 220 are selectively positioned (manually by an operatoror automatically without an operator) via internal motion control servomotors that are under command of a motion control system. Image data areacquired, captured, and if desired archived for further analysis.

Articulated Inspection Scope

FIGS. 2-4 show inspection of a gas turbine by insertion (FIG. 2) of anarticulated inspection scope embodiment 60 into a combustor 34inspection port 36. For maneuvering clearance of the scope 60 about theconfines of a gas turbine installation, inspection scope 60 has afolding knuckle, so that the scope can be folded into a generallyL-shape profile about half as long as an elongated scope. Once the scope60 is positioned within the inspection port 36, the knuckle isstraightened, as shown in FIG. 3. After the inspection scope 60 isaffixed to the inspection port 36 it may be utilized to inspect tocombustor internal components by rotating and extending its camera head.In FIG. 4, as the scope 60 is further extended and its camera headarticulated images of the Row 1 vanes and leading edge of Row 1 bladesmay be acquired. If the turbine rotor is in turning mode, images of allRow 1 blades may be captured as they rotate past the camera head fieldof view.

Referring to FIG. 5, the inspection scope 60 has three main componentsections: extension tube section 62 (see FIGS. 5-9); motor can 64 (FIGS.5, 10-12); and camera tip 66 (FIGS. 5, 12-15) that are capable ofperforming the following five degrees of motion freedom:

Ω—gross rotation;

T—telescoping extension;

Φ—camera head articulation;

E—camera head tip extension; and

θ—camera head rotate/pan.

The extension tube section 52 has a mounting tube 70 and mounting collar72 that are attached to an inspection port, such as the combustorinspection port 36. Motor housing 74 is attached to the opposite end ofmounting tube 70 distal the mounting collar 72 and houses the servomotors necessary to perform the Ω and T degrees of motion. Threetelescoping tubes 75-77 collapse into the mounting tube 70 for providingthe T directional motion.

As shown in FIGS. 6 and 7, spring loaded locking knuckle 80 enables theentire inspection scope 60 to fold for compact maneuvering about theturbine 30, as shown in FIG. 2 and described above. Locking sleeve 77Aslides over telescoping tube 77 and restrains knuckle 80 therein whenthe inspection scope 60 is in is locked inspection position as shown inFIG. 7.

As shown in FIG. 5, motor can 64 houses the servo motors necessary toposition motorized articulating joint 82 that provides the Φ degree ofmotion, the camera head 66 head extension motion E via the camera headtelescoping extensions 84, 86 and the camera head 88 rotate/pan degreeof motion θ. The camera head 88 includes camera ports 90, 92 forrespective axial and lateral fields of view (FOV).

FIG. 8 is a detailed view of the motor housing 74, showing two coaxiallynested, independently driven large and small diameter gears in therotation hub 100. Rotate drive gear 102 is driven by the rotate servomotor 104, for effectuating the Ω motion by rotating the larger diametergear in the rotation hub 100. Telescope extension drive screw 106 isrigidly coupled to the smaller diameter gear in rotation hub 100, thatin turn engages the extend drive gear 108. Extend servo motor 110 isresponsible for effectuating the T motion by rotating the smallerdiameter in the rotating hub 100. Mounting collar 72 attaches to adapterring 112, that is in turn attached to an inspection port, such as thecombustor inspection port 36. As shown in FIG. 9, the adapter ringincludes a plurality of peripheral threads 114 that are engaged withmating internal threads within the collar 72. The adapter ring 112 hasmounting holes 116 for receipt of tapered head machine screws 118. Thescrews 118 may be captively mounted within adapter ring 112. Otherconfigurations of adapter ring or other forms of base that affixes thescope to an inspection port may be substituted for the adapter ring 112.

Referring to FIG. 10, motor can 64 has a motor can housing 120 with apair of spaced apart ear-like motor can pivots 122. Articulate motionservo motor 124 rotates drive screw 126 that imparts the Φ articulatingmotion by tipping camera pivoting hub 128. The tipping motion axis 132is established between camera hub pivot 130 that is rotatively coupledto the motor can pivot 122. Offset link 133 is coupled to drive screw126 and converts linear motion to rotational motion about tipping motionaxis 132.

Motor can housing 120 also contains camera pan/rotate servo motor 134that imparts the θ degree of motion on camera head 66, as shown in FIG.11. Servo motor 134 drives bevel gear train 136, which in turn includesthe driven bevel gear that is rotatively captured within camera pivotinghub 128, for in turn rotating the rotating hub 129. The rotating hub 129is rigidly coupled to the camera head telescoping extension 84. Cameratip telescoping extensions 84 and 86 are extended and retracted in the Emotion degree by extension servo motor 140, that in turn engages lineardrive screw 142. The drive screw 142 includes drive pulley 144, overwhich passes tensioned cable 146. Slave pulley 148 is attached to camerahead 88 and is also coupled to cable 146. Coil spring 150 is interposedbetween camera head 88 and rotating hub 129, and biases them away fromeach other, thereby tensioning cable 146. It follows that selectivetranslation of the drive screw 142 by the extension servo motor 140moves the camera head 88 to the left and right in the figure (motion E).

FIGS. 13-15 show the camera head 88 that has a clamshell constructionwith camera head housing 152 and selectively removable cover 15. Camera156 has a field of view (FOV) through “camera 1” port 90, extendingalong the central axis of the camera head 88. Camera 158 has a field ofview (FOV) through “camera 2” port 92, extending laterally or normal tothe central axis of the camera head 88. Camera 156 generates its imagethrough prism 160. Cameras 156, 158 are known auto-focusing USB camerasof the type routinely used with personal computers. Light emittingdiodes (LEDs) 162 and 164 provide illumination for the cameras 156, 158during internal inspection of power generation machinery.

Inspection scope 60 is externally cooled by a cooling air line 170 andpressurized cooling air source 172 (e.g., compressed air), schematicallyshown in FIG. 15. Cooling air passes through the scope 60 to transferheat away from the instrument, where it exhausts through gaps within thescope outer surface, such as the camera ports 90, 92, the prism 160,around the cameras 156, 158 and the LEDs 162, 164. Those gapseffectively function as cooling air exhaust ports. Cooling airexhausting the various cooling ports helps transfer heat out of thescope 60 and helps create a thermal barrier around the camera head 88that is relatively cooler than the not fully cooled turbine 30 internaltemperature. In this manner the inspection scope 60 can be inserted intostill hot shut-down turbine many hours before it cools to ambient airtemperature. In this manner inspection can be initiated many hours—andpossibly days—earlier than was permissible with known inspectionsystems. In this manner an inspection process can be initiated andcompleted earlier in a turbine service period than was possible in thepast, possibly reducing the aggregate maintenance cycle time.

Camera Inspection Scope Control and Operation

Inspection scope 60 positioning along its five degrees of motion areaccomplished by energizing the five previously described precisionmotion control servo motors 104 (Ω), 110 (T), 124 (θ), 124 (Φ), and 140(E). The servo motors have associated encoders that provide motorposition information feedback for use by the controller of a knownmotion control system. FIG. 16 is block diagram of an exemplary motioncontrol system of the present invention. The previously describedinspection scope 60 hardware is designated by dashed line 60, and is incommunication with control box 180, also designated by dashed line, byway of known communication pathways, such as multi-pathway cable 192 anda USB camera cable.

Control box 180 includes first and second power supplies 182, 184 forpowering motion controller 186 and motion controller motor drive 188.All of components 182-188 are of known design utilized for industrialmotion control systems. The motion controller 186 issues commands to themotion controller motor drive 188 for energizing and reversing theinspection scope 60 servo motors 104 (Ω), 110 (T), 124 (θ), 124 (Φ), and140 (E). For brevity all such motors are collectively referred to as“servo motors”. The respective servo motors have associated encodersthat generate encoder signals indicative of the scope position withinits respective range of motion. For example, the encoder associated withservo motor 104 generates a rotational position signal indicative of thegross rotational position (Ω) of the extension tube portion 62. Positionsignal information from each encoder is accessed by the motioncontroller 186. The motion controller 186 correlates respective motorencoder signals with inspection scope 60 spatial position. Digital lightcontroller 190 controls the LED 162, 164 luminal output and on/off, andcommunicates with the motion controller 186. The motion controller 186also controls cooling air flow into and through the inspection scope 60,for example flow rate out the cooling port 174.

Motion controller 186 has an optional wireless communication capability194. Hardwired data pathway 198, for example a cable transmittingcommunications signals in conformity with Ethernet protocol, is incommunication with a host controller 200. An exemplary host controller200 is a personal computer with internal memory capacity and if desiredexternal memory 202. The host controller computer 200 also receives andprocesses image data from camera 156 (USB Camera 1) and from camera 158(USB Camera 2), that may be processed. The computer 200 may archive orotherwise store raw or processed image data in memory 202. Inspectionscope 60 can be positioned under human command and control, such as viajoystick 204 and/or HMI viewing/touch screen 206. Images from thecameras 156, 158 can be viewed by HMI viewing screen 206. Optionally thecomputer 200 may have wireless communication capability, for example tocommunicate with other computers, including for example a tabletcomputer 210 with HMI, such as for example a tablet computer. FIG. 17shows an exemplary tablet computer HMI display screen including Camera 1image display 212, Camera 2 image display 214, probe positioninformation display 216 and an HMI control interface 218 formanipulating inspection scope 60 position. The tablet computer 210 mayhave direct communications capability with the motion controller 186,without the need to communicate through the host controller computer200.

Blade/Vane Inspection Scope

A blade/vane inspection scope 220 embodiment is shown in FIGS. 18-20.This embodiment is particularly suitable for inspection within theconfines of a gas turbine 30 turbine section 38, between rows ofrotating blades and stationary vanes. FIG. 18 shows a pair of inspectionscopes 220 respectively mounted to each of the Row 1 inspection port 50and Row 2 inspection port 52. However, at the discretion of aninspection team a single inspection scope 220 may be mounted to aselected inspection port or more than two inspection scopes 220 may bemounted to the turbine 30 simultaneously during an inspection procedure.Similarly, an inspection team at its discretion may also operate one ormore of the inspection scope 60 embodiments simultaneously with orwithout the inspection scope 220 embodiment in any inspection procedure.

As shown in FIGS. 19 and 20 the inspection scope 220 embodiment ismounted to a gas turbine inspection port (here a Row 1 inspection port50) by mounting flange 222. Linear drive 224 with an associated servomotor and encoder translates the inspection scope in the telescopingextension position motion degree T. Rotational drive 226 with anassociated servo motor and encoder rotates the inspection scope in thecamera rotate/pan motion degree θ. Bore scope 228 is mechanicallycoupled to the linear drive 224 and rotational drive 226, and has acamera head 230 that captures within its field of view (FOV). The camerahead 230 includes a pivoting prism 232 whose motion in the articulationΦ motion degree is imparted by an associated servo motor and encoder.The bore scope 228 is of known construction and includes fiber opticlenses 234 and auxiliary external lighting (not shown) that illuminateand transmit images within the camera head field of view to camera 336.The camera 236 may be an auto focusing USB camera that is coupled to amotion control system, such as shown in FIG. 16. General motion controland positioning of the inspection scope 220 along its motion degrees Φ,θ and T and camera image capture are performed as previously describedwith respect to the inspection scope embodiment 50.

The inspection scope 220 includes an external cooling system forinspection within a turbine 30 cool-down phase when the turbine section30 still has an elevated temperature of up to approximately 150° C. Aswas described with respect to the inspection scope embodiment 50, thecooling system includes an air line 170 running in parallel to or withinthe bore scope 228 that expels cooling air obtained from a cooling airsource through one or more functional cooling air exhaust ports, such asaround the camera head 230.

The three motion degrees Φ, θ and T in the blade/vane inspection scope220 embodiment are sufficient to obtain complete images of the leadingor trailing sides of all rotating turbine blades within a given rowwhile the turbine rotor is spinning in turning gear mode. For example inFIG. 18 the leading side of each of the Row 1 turbine blades 44 can beinspected by the inspection scope 220 that is positioned in inspectionport 50. As each individual blade rotates within the camera head 230field of view its image is captured by the associated control system. Apartial or full series of blade images can be obtained during a singlerotor 40 rotation while the turbine 30 is in turning gear mode. A singlecamera head 230 field of view may not capture the full radial length anarea of interest on a turbine blade. By repositioning the camera headtilt angle Φ or inserting/retracting the bore scope 228 along the Tfreedom degree the camera field of view can be repositioned radiallyalong the blade or vane length. Images captured at different blade/vaneradial positions can be combined to create an aggregate image of theentire blade. Similarly, an image of the trailing edge of each blade 44in Row 1 can be captured by positioning an inspection scope 220 inturbine inspection port 52, as was done for the leading edges.

Exemplary Turbine Inspection Procedures

The camera inspection system of the present invention provides thecapability of automatic positioning and image capture of an inspectioncamera field of view relative to an area of interest with a turbine,such as a gas turbine, without human intervention. After inspectionscope positioning sequence information is provided to the system,subsequent inspections are repeatable by different inspection teams,regardless of their individual inspection scope positioning skill orinspection speed. Automated inspections can be completed quicker, withless likelihood of human-created errors, as compared to known inspectionprocedures. Further explanation of the inspection methods of the presentinvention will be with reference to inspection of an exemplaryindustrial gas turbine.

Inspection scope positioning sequence information may be obtained byinstalling an inspection scope embodiment of the present invention on aselected inspection port and orienting all controlled motions to aninitialized or “start” position. A human inspector guides the inspectionscope through the control system HMI, e.g., by use of a joystick ortouch screen pad, through a navigated path within the turbine that isrecorded within one or both the control system controllers/hostcomputer. The navigation path is chosen to orient the inspection scopecamera head field of view within area of interest without causingundesirable impact of the scope with turbine internal components.

The control system retains the navigation path information from theinitial human-controlled inspection and can subsequently repeat theinspection scope positioning sequence for future inspection cycles onthe same turbine or other turbines having the same internal structure.For example, a navigation path sequence can be performed on a singletest turbine and the sequence can be communicated to other remote sitesfor use by inspection teams inspecting the same structure gas turbinelocated at that site. In the field, an inspection team may be concernedthat a different gas turbine may have variations in internal structurefrom the original gas turbine. The field team may review the storednavigation path individual step by step, with local override toaccommodate any path variations needed for the field installationturbine to perform an inspection, or may choose to program a newnavigation path dedicated to the field location turbine.

Navigation paths alternatively can be determined in virtual space by ahuman inspector simulating a navigation path in a simulated turbine andrecording the path for subsequent use in actual turbine inspections. Asanother alternative, a scope inspection simulation program can prepare asuggested inspection navigation path for review and approval by a humaninspector.

A navigation path sequence can move the camera head field of view fromone position of interest to another position of interest. For example,an inspection scope can be affixed to a combustor inspection port,whereupon the inspection system can capture and record images ofinternal components within the combustor, then move to the leading edgeof Row 1 vanes, pass through those vanes and inspect the leading edge ofRow 1 blades. If the turbine is in turning gear mode the camera head canrecord sequentially the same image for each blade during a single rotorrotation.

When in a navigation path position the camera head may be repositionedto obtain image information from different camera fields of view fromthe same reference point. The various images taken from the samereference point can be combined to obtain a composite or “stitched” viewof the structural elements, or to take a virtual “tour” of any or allportions of the turbine interior.

Rather than move the inspection scope camera head field of view from oneposition to another, it is also possible to move the turbine componentareas of interest within the field of view of a stationary camera head.For example, an inspection scope inserted between blade and vane rowscan capture an image of each blade rotating within the camera field ofview, whether the turbine is in turning gear mode or whether an operatormanually “bumps” each blade of a completely stopped turbine rotorsequentially in front of the camera head.

Although various embodiments which incorporate the teachings of thepresent invention have been shown and described in detail herein, thoseskilled in the art can readily devise many other varied embodiments thatstill incorporate these teachings. For example, “optical images” ofturbine internal component can be obtained in the visible light spectrumor in the infrared spectrum. The inspection scope motion degrees do nothave to be limited to those exemplary motions enabled by the servomotors 104 (Ω), 110 (T), 124 (θ), 124 (Φ), and 140 (E). Scope motiondoes not have to be imparted by servo motors, and can include knownalternative pneumatic or other motion control systems.

What is claimed is:
 1. A system for non-contact internal inspection ofpower generation machinery, comprising: a base for affixation to a powergeneration machine inspection port; an inspection scope having aproximal end coupled to the base, and an extendable elongated bodydefining a central axis, extended and driven by a linear drive that iscapable of remote control and actuation by a control system; a camerahead coupled to a camera, having a field of view, the camera headcoupled to the inspection scope distal the base, that are capable ofremote control and image capture by a control system; an articulationdrive, coupled to the camera head and the control system, that iscapable of remote control and actuation by a control system, forarticulating the camera head and field of view relative to theinspection scope central axis; and a control system coupled to theinspection scope linear and articulation drives and the camera, forautomatically guiding and positioning the inspection scope and camerafield of view along a pre-designated pre-recorded non-contact navigationpath of linear and articulation drives actuation instructions within apower generation machine to an internal area of interest without humanintervention and for capturing a camera image thereof without humanintervention.
 2. The system of claim 1, wherein the control systemautomatically and sequentially positions the camera field of view toplural areas of interest along the navigation path and capturesrespective images thereof.
 3. The system of claim 2, wherein thesequential positioning and image capture is performed automaticallywithout human intervention.
 4. The system of claim 2, wherein thesequential positioning and image capture allows human intervention in atleast one of the sequential positioning steps before proceeding to thenext step along the navigation path.
 5. The system of claim 2, whereinthe inspection scope moves along the navigation path between sequentialpositions.
 6. The system of claim 2, wherein the inspection scoperemains static between sequential positions, the plural areas ofinterest within the machine move along the navigation path, and thecontroller causes the camera to capture images of the plural areas ofinterest when they are within the camera field of view.
 7. The system ofclaim 2, wherein images of plural areas of interest are combined toproduce a composite image.
 8. The system of claim 1, wherein the controlsystem stores respective images of an area of interest taken at pluraltimes and allows said images to be overlaid for inspection comparison.9. The system of claim 1, wherein the pre-recorded navigation pathdesignation is selected from the group consisting of: human controlledpositioning of an inspection scope within a power generation machine ofthe same type along a selected navigation path, and recording saidnavigation path for subsequent replication by an inspection scopecontrol system; human controlled simulated positioning of a virtualinspection scope within a virtual power generation machine of the sametype along a selected navigation path, and recording said navigationpath for subsequent replication by an inspection scope control system;and simulated positioning of a virtual inspection scope and virtualpower generation machine of the same type along a simulated selectednavigation path without human intervention, and recording saidnavigation path for subsequent replication by an inspection scopecontrol system.
 10. A method for non-contact internal inspection ofpower generation machinery, comprising the steps of: providing aninternal inspection system having: a base for affixation to a powergeneration machine inspection port; an inspection scope having aproximal end coupled to the base, and an extendable elongated bodydefining a central axis, extended and driven by a linear drive that arecapable of remote control and actuation by a control system; a camerahead coupled to a camera, having a field of view, the camera headcoupled to the inspection scope distal the base, that is are capable ofremote control and image capture by a control system; an articulationdrive, coupled to the camera head and the control system, that iscapable of remote control and actuation by a control system, forarticulating the camera head and field of view relative to theinspection scope central axis; and a control system coupled to theinspection scope linear and articulation drives and the camera, forautomatically guiding and positioning the inspection scope and camerafield of view along a pre-designated pre-recorded non-contact navigationpath of linear and articulation drives actuation instructions within apower generation machine of the type being inspected to an internal areaof interest without human intervention and for capturing a camera imagethereof without human intervention; affixing the base to a power machineinspection port; providing the pre-recorded non-impact navigation pathto the control system; and inspecting the power machine by automaticallypositioning the inspection scope and camera field of view along thenavigation path with the control system without human intervention andcapturing a camera image thereof without human intervention.
 11. Themethod of claim 10, wherein during the inspecting step the controlsystem automatically and sequentially positions the camera field of viewto plural areas of interest along the navigation path and capturesrespective images thereof.
 12. The method of claim 11, wherein theinspecting step is performed automatically without human intervention.13. The method of claim 11, wherein the sequential positioning and imagecapture steps within the inspecting step allow human intervention in atleast one of the steps before proceeding to the next step along thenavigation path.
 14. The method of claim 11, further comprising movingthe inspection scope along the navigation path between sequentialpositions during the inspecting step.
 15. The method of claim 11,further comprising during the inspecting step: maintaining theinspection scope in a static position with the control system; movingthe plural areas of interest within the machine along the navigationpath; and capturing images of the plural areas of interest as they moveinto the camera field of view, with the camera and the control system.16. The method of claim 11, further comprising combining images selectedfrom the group consisting of: combining images of plural areas ofinterest and producing a composite image; and combining images taken atplural times and overlaying the images.
 17. The method of claim 10,wherein the pre-recorded navigation path is determined by a methodselected from the group consisting of: human controlled positioning ofan inspection scope of the type used in the inspecting step along aselected navigation path within a power generation machine of the typebeing inspected, and recording said navigation path for subsequentreplication by the control system; human controlled simulatedpositioning of a virtual inspection scope of the type used in theinspecting step within a virtual power generation machine of the typebeing inspected along a selected navigation path, and recording saidnavigation path for subsequent replication by the control system; andsimulated positioning of a virtual inspection scope and virtual powergeneration machine of the type used in the inspecting step along asimulated selected navigation path without human intervention, andrecording said navigation path for subsequent replication by the controlsystem.
 18. The method of claim 10, wherein the power machine isselected from the group consisting of industrial gas turbines, steamturbines and generators.
 19. A method for non-contact inspecting anindustrial gas turbine, comprising the steps of: shutting down a gasturbine operation; providing an internal inspection system having: abase for affixation to an inspection port of the turbine; an inspectionscope having a proximal end coupled to the base, and an extendableelongated body defining a central axis, extended and driven by a lineardrive that are capable of remote control and actuation by a controlsystem; a camera head coupled to a camera, having a field of view, thecamera head coupled to the inspection scope distal the base, that is arecapable of remote control and image capture by a control system; anarticulation drive, coupled to the camera head and the control system,that is capable of remote control and actuation by a control system, forarticulating the camera head and field of view relative to theinspection scope central axis; and a control system coupled to theinspection scope linear and articulation drives and the camera, forautomatically guiding and positioning the inspection scope and camerafield of view along a pre-designated pre-recorded non-contact navigationpath of linear and articulation drives actuation instructions within thegas turbine to an internal area of interest without human interventionand for capturing a camera image thereof without human intervention;cooling the gas turbine to an internal temperature of less than 150° C.(300° F.); affixing the base to an inspection port of the gas turbine;providing the pre-recorded non-impact navigation path to the controlsystem; inspecting the gas turbine by automatically positioning theinspection scope and camera field of view along the navigation path withthe control system without human intervention and capturing a cameraimage thereof without human intervention; and storing the camera imagefor review.
 20. The method of claim 19, wherein the pre-recordednavigation path is determined by a method selected from the groupconsisting of: prior human controlled positioning of an inspection scopeof the type used in the inspecting step within the actual inspected gasturbine along a selected navigation path, and recording said navigationpath for subsequent replication by the control system of the inspectionscope used in the inspecting step; prior human controlled positioning ofan inspection scope of the type used in the inspecting step withinanother gas turbine having the same type of internal structure as theactual inspected gas turbine along a selected navigation path, andrecording said navigation path for subsequent replication by the controlsystem of the inspection scope used in the inspecting step; humancontrolled simulated positioning of a virtual inspection scope of thetype used in the inspecting step within a virtual power generationmachine of the type being inspected along a selected navigation path,and recording said navigation path for subsequent replication by thecontrol system of the inspection scope used in the inspecting step; andsimulated positioning of a virtual inspection scope and virtual powergeneration machine of the type used in the inspecting step along asimulated selected navigation path without human intervention, andrecording said navigation path for subsequent replication by the controlsystem of the inspection scope used in the inspecting step.